Clarke WE6490 Owner's manual

Brand: Clarke

Model: WE6490

Category: Welding System

Type: Owner's manual

This manual is also suitable for

WE_85 80E@_- WE__ _E @

131E- ,2_TE

_SYA !50

Congratulations on the purchase of your new 1311"1_welder. Before attempting

to operate this machine, please read this manual thoroughly and follow all

instructions carefully. By doing so you wilt help to ensure the safety of both

yourself and others around you, and at the same time, you should look forward

to long and trouble free service from your I_lll'_J welder.

1.0 Safety Precautions 4

1A.0 Normes de Securite 6

2.0 Arc Welding - How it Works 8

3.0 Thermal Overload Protection 8

4.0 Electrical Connection 9

5.0 Preparation for Welding 9

Diagram 1 11

6.0 Welding Technique 12

7.0 Welding Pitfalls 13

8.0 Maintenance and Servicing 13

9.0 Welder Doesn't work? 16

10.0 Types of Joints 17

Parts drawing and list - Wiring diagram WE6485 18-19

Parts drawing and list - Wiring diagram WE6490 20-21

Parts drawing and list - Wiring diagram WE6519 22-23

Parts drawing and list - Wiring diagram WE6534 24-25

Parts drawing and list - Wiring diagram WE6537 26-28

Parts drawing and list - Wiring diagram WE6522 29-30

GUARANTEE

For 12 months from the date of purchase, Clarke warranties this welder against failures

due to defects in material or workmanship. This warranty does not cover expendable

parts such as contact tips or nozzles, which are consumed during normal welder

operation. If the welder fails within 12 months from the date of purchase, you must

contact Clarke Power Products at 1-800-227-9603 to acquire a Return Authorization

Number. Once you have acquired a Return Authorization Number from Clarke, return the

product to the following address - postage or UPS paid:

Clarke Power Products, Inc.

28740 Glenwood Road

Perrysburg, OH 43551

Attn: Warranty Repair

We will examine the product. If the problem is due to a manufacturing defect, we will

repair or replace the product at no charge and return it to you postage or UPS paid. If the

problem is due to misuse, abuse, the product has been modified, or is out of warranty, we

will contact you with a repair estimate and ask for a credit card number for payment. After

the product has been repaired, it will be returned postage or UPS paid. This warranty

applies only while this product is used in the United States. This warranty gives you

specific legal rights, and you may also have other rights which vary from state to state.

1.0 SAFETY PRECAUTIONS

1.1 GENERAL INSTRUCTIONS

Make sure this manual is carefully read and understood by the

operator.

1.2 LOCATION

Welding processes of any kind can be dangerous not only to

the operator but to any person situated near the equipment if

safety and operating rules are not strictly observed.

These are the main precautionary measures to observe:

• Operators should protect their body by wearing closed,

non-flammable protective clothing, without pockets or turned up

trousers.

• The operators should wear a non-flammable welding

helmet designed so as to shield the neck and the face. It is

necessary to keep the protective lens always clean and to

replace it when broken or cracked. It is advisable to put a

transparent glass between the lens and the welding area.

Welding should be done in a close area that does not open into

other working areas.

• The operators should never look at the welding arc without

the correct protection for the eyes. They should always wear

safety glasses with side shields to protect from flying particles.

• The welding process must be performed on metal coatings

thoroughly cleaned from layers of rust or paint to avoid production

of harmful fumes. The parts degreased with a solvent must be

dried before welding.

• Welding should never be done on metals or coated metals

containing zinc, mercury, chronium, graphite, lead cadmium or

beryllium unless the operator and the people standing in the same

area use an air-supplied respirator.

1.3 SAFETY INSTRUCTIONS

For your safety, before plugging in the welder, closely follow these

instructions:

• When working in a confined space, the welder must be

kept outside the welding area and the ground cable should be

fixed to the workplace. Never work in a damp or wet area, in

these conditions.

• Do not use damaged input or welding cables.

• The welding torch should never be pointed at the operator's

or another person's body.

• The welder must never be operated without its panels as

this could cause serious injury to the operator and could damage

the equipment.

1.4 FIRE PREVENTION

Make sure that appropriate fire prevention devices are available

near to the welding area;

All combustible material must be removed from the welding area.

1.6 ELECTRIC SHOCK

DANGER - ELECTRIC SHOCK CAN BE FATAL

Ifa person isfound unconscious and electric shock issuspected,

do not touch the person ifthey are in contact with any electrical

wires. Disconnect power from the machine and then use First

Aid. Dry wood, and other insulating material can be used to move

electrical cables, if necessary, away from the person.

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2.0 ARC WELDING - HOW IT WORKS

Arc welding is a process by which two pieces of metal are joined

together using the heat developed by an electric arc between

the workpiece and an electrode (welding material).

The electrode is connected to one output side of the same

transformer. When the electrode comes into contact with the

workpiece an arc is struck. The high temperature of the arc melts

the electrode into the joint of the work piece and fusion occurs.

MIN/MAX AMPS 55-90 30-90 40400 40-200 45-250 60-150

ELECTRODES 1/16-5/64 1/16-5/64 1/16-3/32 1/16-3/16 5/64-15/64 3/32-i/8

OPEN CRCUT

V(_)I_TS -37 -37 .48 .48 52 148

I I

VOLTS!PHASE 120/1 120/1 120/1 220/1 220/1 220/1

MAX INPUT

owE Ps 113 113 114 123 132 .13

DIM. 15X9X11 17X10X12 17X10X12 _11Xi5 3_16x1617x12x10

I I I I

V_IGHT 28LBS 29LBS 34LBS 75LBS 150LBS 31LBS

P TNuMBER'WEISS'WE 90'WE6519'WE65 WE6522

3.0 THERMAL OVERLOAD PROTECTION

If the duty cycle of the welder is exceeded, a thermostat will

automatically cut the power to prevent the machine from burning

out. If this should happen you will have to wait approximately 30

minutes until the transformer cools down. Then the thermostat

will automatically reset itself and you can continue welding: The

thermostat is a protective safety device and no harm will normally

be done to the transformer unless it is frequently over loaded, in

which case damage will eventually result. For the modes180E,

95E and EasiArc 150 the intervention of the thermostat is

indicated by the lighting of the ON/OFF switch.

4.0 ELECTRICAL CONNECTION

The wires in the input cable of this machine are colored in

accordance with the following code:

120V. 230V.

Green Ground Green & Yellow Ground

White Neutral Blue Live

Black Live Brown Live

120 Volts 20Amp grounded plug: Model 80E - 95E - 131E.

230 Volts grounded plug: Model 240TE

WARNING: This machine must be grounded.

Ifyou intend on using an extension cord make sure the wire cable

size is adequate in diameter.

Ifyou are in doubt about electrical connections consult a qualified

electrician. Do not attempt electrical repairs yourself.

5.0 PREPARATION FOR WELDING

1 With the On/Off switch (item B) in the Off position, connect

the welding leads as follows. (Does not apply to models 80E,

95E and Easi Arc 150 which have fixed leads):

• Connect the ground lead (item N) to the ground terminal

which is the black knob (item F) identified by the ground

symbol (see diagram 1), and secure the ground clamp (item

M) to the workpiece (item L). Note: For good contact the

ground clamp must be attached to the clean bare metal, not

painted.

• Connect the welding lead (item G) to the electrode terminal,

which is the black knob (item E) identified by the electrode

holder symbol (diagram 1) and secure an appropriate welding

rod (item I) by its bare end into the jaws of the elctrode holder

(item H). Note: All connections should be a good metal contact.

Clean with a wire brush where necessary.

2 Thesize(diameter)ofweldingrodshouldbeapproximately

thesameasthethicknessofmetalto bewelded.An appropriate

currentmustbe selectedbyturningthelargehandwheel(itemC)

untiltheslidingindicator(itemD)inthetopofthemachineshows

the required amperage setting. With practice you will gain a

feel for the correct amperage setting for differentwelding rod

thicknesses.

Forbeginnersthetablebelow givessome usefulguidelines.

15/64" 240-250

3 To assemble face shield, first place the darkened plastic

window in the recessed window area in the body. Secure in place

using the two plastic screws fasteners provided. Locate the

handle fixing into the slot in the shield body, press firmly and

rotate through 90 degrees until the lug locates into the hole in

the shield body.

DIAGRAM 1

A Power Cable

B ON/OFF Switch

C Handwheel

D Amperage Indicator

E Electrode Terminal

F Ground Terminal

G Welding Lead

H Electrode Holder

I Electrode

L Workpiece

M Ground Clamp

N Ground Cable

GROUND CLAMP SYMBOL -

IDENTIFIES GROUND

TERMINAL (BLACK KNOB)

ELECTRODE HOLDER SYMBOL -

IDENTIFIES ELECTRODE

TERMINAL (BLACK KNOB)

{H"

6.0 WELDING TECHNIQUE

1 Plug your welder into the correct socket and switch on using

the ON/OFF switch (Item B). NOTE (for models 80E, 95E and Easi

Arc 150): If the machine stops at any time and the ON/OFF switch

lights, the thermostat has intervened. Wait for a few minutes while

the transformer cools down and when the ON/OFF switch goes out

again welding can begin.

2 Particularly for beginners, the most difficult aspect of the arc

welding process isthat of striking an arc. We strongly recommended

that you practice on pieces of scrap metal to get the feel of

the operation, before you start on an actual welding job.

3 Hold the electrode about 3/8" from the workpiece and at an

angle of about 70 degrees to 80 degrees to the work surface; take

care not to accidentally touch the workpiece until you are ready to

begin.

4 Holding the welding mask close to your face, give a short

stroke with the electrode on the workpiece. As soon as the arc is

struck, lightly withdraw the electrode from the workpiece to leave a

tiny gap of around 1/16". The current will flow across the gap with a

crackling noise and brilliant arc. Continue to weld in one direction,

maintaining the small gap as you go. At the end of the run, just

withdraw the electrode fully from the workpiece.

NOTE: When you strike an arc be sure to withdraw the electrode

fairly swiftly to leave the 1/16" gap, otherwise the electrode will weld

itself to the workpiece. Should this happen give the electrode a short

sharp jerk to free it and, if necessary strike the arc again.

5 Inspect the job carefully. With a correct combination of rod

size and amperage setting, the area of the weld should be a com-

plete fusion of the electrode metal being joined. Slag forming on

the surface should be chipped away with a hammer.

If the resulting weld looks irregular or messy, or shows signs of

porosity or slag contamination, you have almost certainly failed

to achieve the correct combination. Do not worry as practice

will soon cure this, and the following tips on welding pitfalls should

help to improve your technique quite quickly.

WARNING: Never look at welding arc, it can seriously

damage your eyes. Always use the face shield provided

or any proper welding mask.

HEALTH WARNING: When welding always make sure

there is adequate ventilation in the working area as the

welding process gives off toxic fumes.

7.0 WELDING PITFALLS

The arc welding technique is an acquired skill and will almost

certainly require considerable practice before perfect results are

obtained. The diagrams below should help to explain pitfalls in

your technique and how to overcome them.

1 Arc distance too short - this causes irregular masses of

weld to be deposited with slag contamination on the uneven

surface.

2 Arc distance too long - this causes poor penetration

resulting in a weak weld with excessive spatter and porosity.

Surface of weld is rough and the arc makes a hissing sound.

3 Electrode moved over workpiece too slowly - this causes

a very wide and heavy deposit which overlaps at the sides. It is

wasteful in terms of both time and electrodes used.

4 Electrode moved over the workpiece too quickly - this

causes poor penetration with a "stringy" and incomplete weld

deposit. Slag is very difficult to remove.

5 Amperage too low - this causes poor penetration and

causes the electrode to stick to the workpiece easily. Also results

in a very irregular and high weld deposit with difficult slag removal.

6 Amperage too high - this causes excessive penetration

with spatter and a deep and pointed crater. It may even cause

holes to be burnt in the workpiece. Burns electrodes very quickly.

/f_" \

7 The perfect weld -with the correct combination of arc length,

amperage regulation and inclination of the electrode you will, with

practice, produce the perfect weld. This should be regular with

uniform ripples and no slag contamination. The arc will make a

steady crackling sound.

8.0 MAINTENANCE AND SERVICING

Your CLARKE arc welder is a simple and robust unit, requiring

virtually no maintenance other than the guidelines shown below:

Keep the ventilation holes in welder clean to avoid the build up

of dirt and oxides inside the machine, this can reduce machine

output.

Check all cables periodically; they must be in a good condition

and free of cracks or cuts.

Always try to avoid getting particles of metal inside the machine

since they could cause short circuits.

Periodically clean the inside of the welder with compressed air

IMPORTANT: unplug the welder before cleaning.

Should you have a problem with your machine contact your local

service agent or CLARKE POWER PRODUCTS, Inc. at

(800)227-9603

9.0 WELDER DOESN'T WORK?

PROBLEM

Power source

stops.

PROBABLE CAUSE POSSIBLE SOLUTION

Thermostatic overload

activated due to

overload.

Power switch light Bad connection

on but no weld between ground clamp

current, and workpiece.

Impurities on base Clean with wire brush.

Unstable arc.

metal.

Porous weld. Dirty base metal. Clean with wire brush.

The thermostatic overload

automatically resets when

the transformer has cooled

(approx. 15 minutes).

Clean or wire brush the

work surface.

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10.0 TYPES OF JOINTS

OPEN SQUARE BUTT JOINT

÷11

Gap varies from _ 6ram to 4 8ram depending

on p_ate thickness

SINGLE VEE BUTT JOINT

1.6mm

........... NOT £ESS THAN 70°

I L

DOUBLE VEE BUTT JOINT

NOT LESS THAN 70 °

1.6mm _ t

SINGLE BEVEL JOINT

DOUBLE BEVEL JOINT

CORNER JOINT

SINGLE FILLET LAP JOINT

DOUBLE FILLET LAP JOINT

SINGLE STRAP JOINT

DOUBLE STRAP JOINT

DOUBLE FILLET TEE JOINT SINGLE FILLET TEE JOINT

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OPERATING MANUAL

Clarke WE6490 Owner's manual

Brand: Clarke

Model: WE6490

Category: Welding System

Type: Owner's manual

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Clarke WE6490 Owner's manual

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Clarke WE6490 Owner's manual

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